U.S. patent application number 14/345033 was filed with the patent office on 2014-12-04 for part mounting facility and part mounting method.
This patent application is currently assigned to HONDA MOTOR CO., LTD.. The applicant listed for this patent is Daisuke Hashimoto, Nobuhiro Kozasa, Koichi Sano, Tomohiro Sugimoto, Hidetoshi Takahashi, Katsuyoshi Tsutsumida. Invention is credited to Daisuke Hashimoto, Nobuhiro Kozasa, Koichi Sano, Tomohiro Sugimoto, Hidetoshi Takahashi, Katsuyoshi Tsutsumida.
Application Number | 20140353116 14/345033 |
Document ID | / |
Family ID | 47914288 |
Filed Date | 2014-12-04 |
United States Patent
Application |
20140353116 |
Kind Code |
A1 |
Kozasa; Nobuhiro ; et
al. |
December 4, 2014 |
PART MOUNTING FACILITY AND PART MOUNTING METHOD
Abstract
A part mounting facility is provided with substantially U-shaped
conveyance paths having return bends, and the substantially
U-shaped conveyance paths are formed by providing conveyance paths,
which are in part mounting work regions, with the return bends. The
substantially U-shaped conveyance paths are connected to each
other, and the upstream-most substantially U-shaped conveyance path
among the connected substantially U-shaped conveyance paths is
connected to the downstream-most substantially U-shaped conveyance
path to enable a workpiece conveyance dolly to circulate along the
conveyance paths.
Inventors: |
Kozasa; Nobuhiro; (Hagagun,
JP) ; Tsutsumida; Katsuyoshi; (Hagagun, JP) ;
Takahashi; Hidetoshi; (Hagagun, JP) ; Hashimoto;
Daisuke; (Hagagun, JP) ; Sugimoto; Tomohiro;
(Hagagun, JP) ; Sano; Koichi; (Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kozasa; Nobuhiro
Tsutsumida; Katsuyoshi
Takahashi; Hidetoshi
Hashimoto; Daisuke
Sugimoto; Tomohiro
Sano; Koichi |
Hagagun
Hagagun
Hagagun
Hagagun
Hagagun
Tokyo |
|
JP
JP
JP
JP
JP
JP |
|
|
Assignee: |
HONDA MOTOR CO., LTD.
Tokyo
JP
|
Family ID: |
47914288 |
Appl. No.: |
14/345033 |
Filed: |
August 28, 2012 |
PCT Filed: |
August 28, 2012 |
PCT NO: |
PCT/JP2012/071671 |
371 Date: |
May 18, 2014 |
Current U.S.
Class: |
198/346.3 |
Current CPC
Class: |
B62D 65/18 20130101;
B62D 65/12 20130101; B65G 17/32 20130101; B65G 17/20 20130101; B62D
65/10 20130101 |
Class at
Publication: |
198/346.3 |
International
Class: |
B65G 17/20 20060101
B65G017/20; B65G 17/32 20060101 B65G017/32 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 19, 2011 |
JP |
2011-203986 |
Claims
1. A part mounting facility for mounting parts on a workpiece
carried on a workpiece conveyance dolly, comprising: conveyance
paths provided in a part mounting work region; and the workpiece
conveyance dolly that travels along the conveyance paths, wherein a
plurality of substantially U-shaped conveyance paths having return
bends is formed by providing the conveyance paths with the return
bends in the part mounting work region, wherein the substantially
U-shaped conveyance paths are connected to each other, and an
upstream-most substantially U-shaped conveyance path among the
connected substantially U-shaped conveyance paths is connected to a
downstream-most substantially U-shaped conveyance path to enable
the workpiece conveyance dolly to circulate along the conveyance
paths.
2. The part mounting facility as defined in claim 1, wherein the
part mounting work region in which the plurality of substantially
U-shaped conveyance paths is provided is provided in a plural
number, and wherein the part mounting facility further comprises a
lift conveyance means which is capable of conveying the workpiece,
carried on the workpiece conveyance dolly provided in an
upstream-side part mounting work region among the plural part
mounting work regions, to a workpiece conveyance dolly provided in
a downstream part mounting work region.
3. The part mounting facility as defined in claim 2, wherein the
lift conveyance means lifts up and conveys the workpiece from the
workpiece conveyance dolly provided in the upstream-side part
mounting work region to the workpiece conveyance dolly provided in
the downstream-side part mounting work region.
4. The part mounting facility as defined in claim 2, wherein the
workpiece is a body of an automobile, and, while the workpiece
carried on the workpiece conveyance dolly provided in the
upstream-side part mounting work region is lifted up and conveyed
by the lift conveyance means to the workpiece conveyance dolly
provided in the downstream-side part mounting work region, parts of
a driving mechanism and a suspension are mounted on the
workpiece.
5. The part mounting facility as defined in claim 1, wherein a
serving conveyance path provided for movement therealong of a part
serving carriage is connected at opposite ends to a mounting work
start position and a mounting work end position of each of the
substantially U-shaped conveyance paths so that the serving
carriage is allowed to move into each of the substantially U-shaped
conveyance path from the mounting work start position and to be
conveyed out into the serving conveyance path from the mounting
work end position.
6. A part mounting method for mounting parts onto a workpiece while
the workpiece is moved along conveyance paths, wherein a plurality
of substantially U-shaped conveyance paths is formed by providing
the conveyance paths with return bends, the method comprising the
steps of: organizing a working group allotted to one workpiece
moving along the substantially U-shaped conveyance paths, the
working group is composed of one or more mounting operators engaged
in a mounting work, beginning at a mounting work start position and
ending at a mounting work end position, for mounting predetermined
plural parts on the workpiece, and a plurality of extra operators;
and performing the mounting work by the working group.
7. The part mounting method as defined in claim 6, wherein the
working group further includes, additional to the mounting operator
or operators, a part transporting operator for transporting a part
from a part storage site to the mounting operator or operators.
8. The part mounting facility as defined in claim 2, wherein a
serving conveyance path provided for movement therealong of a part
serving carriage is connected at opposite ends to a mounting work
start position and a mounting work end position of each of the
substantially U-shaped conveyance paths so that the serving
carriage is allowed to move into each of the substantially U-shaped
conveyance path from the mounting work start position and to be
conveyed out into the serving conveyance path from the mounting
work end position.
9. The part mounting facility as defined in claim 3, wherein a
serving conveyance path provided for movement therealong of a part
serving carriage is connected at opposite ends to a mounting work
start position and a mounting work end position of each of the
substantially U-shaped conveyance paths so that the serving
carriage is allowed to move into each of the substantially U-shaped
conveyance path from the mounting work start position and to be
conveyed out into the serving conveyance path from the mounting
work end position.
10. The part mounting facility as defined in claim 4, wherein a
serving conveyance path provided for movement therealong of a part
serving carriage is connected at opposite ends to a mounting work
start position and a mounting work end position of each of the
substantially U-shaped conveyance paths so that the serving
carriage is allowed to move into each of the substantially U-shaped
conveyance path from the mounting work start position and to be
conveyed out into the serving conveyance path from the mounting
work end position.
Description
TECHNICAL FIELD
[0001] The present invention relates to a part mounting facility
and a part mounting method wherein parts are mounted on a workpiece
set on a workpiece conveyance dolly while the dolly travels along a
conveyance path.
BACKGROUND ART
[0002] Some of part mounting facilities are known as implementing
an assembly method to complete a single assembly or product
(hereinafter referred to as "workpiece" by a particular number (a
single or plural) of human operators during one cycle of operation
(i.e., cell production system), as disclosed, for example, in
Patent Document 1. According to such part mounting facilities, the
particular number of human operators moves along with the workpiece
and complete a part mounting operation while the workpiece moves
over one-cycle distance.
[0003] However, the part mounting facility disclosed in Patent
Document 1 may encounter a problem that as to a workpiece having a
large number of part items to be mounted, working loads on the
human operators increase too much due to an increase in work
mastering man-hours. Furthermore, an undue increase in the working
loads will hinder the human operators from performing a highly
efficient mounting operation.
PRIOR ART LITERATURE
Patent Documents
[0004] [Patent Document 1] Japanese Patent Application Laid-Open
Publication (JP-A) No. 2003-251575
SUMMARY OF INVENTION
Technical Problem
[0005] An object of the present invention is to provide a part
mounting facility and a part mounting method which are able to
suppress working loads on the human operators even when the number
of part items to be mounted to a workpiece is relatively large.
Solution to Problem
[0006] In the invention according to a first aspect, there is
provided a part mounting facility for mounting parts on a workpiece
carried on a workpiece conveyance dolly, comprising: conveyance
paths provided in a part mounting work region; and the workpiece
conveyance dolly that travels along the conveyance paths, wherein a
plurality of substantially U-shaped conveyance paths having return
bends is formed by providing the conveyance paths with the return
bends in the part mounting work region, wherein the substantially
U-shaped conveyance paths are connected to each other, and an
upstream-most substantially U-shaped conveyance path among the
connected substantially U-shaped conveyance paths is connected to a
downstream-most substantially U-shaped conveyance path to enable
the workpiece conveyance dolly to circulate along the conveyance
paths.
[0007] In the invention according to a second aspect, preferably,
the part mounting work region in which the plurality of
substantially U-shaped conveyance paths is provided is provided in
a plural number, and the part mounting facility further comprises a
lift conveyance means which is capable of conveying the workpiece,
carried on the workpiece conveyance dolly provided in an
upstream-side part mounting work region among the plural part
mounting work regions, to a workpiece conveyance dolly provided in
a downstream part mounting work region.
[0008] In the invention according to a third aspect, preferably,
the lift conveyance means lifts up and conveys the workpiece from
the workpiece conveyance dolly provided in the upstream-side part
mounting work region to the workpiece conveyance dolly provided in
the downstream-side part mounting work region.
[0009] In the invention according to a fourth aspect, preferably,
the workpiece is a body of an automobile, and, while the workpiece
carried on the workpiece conveyance dolly provided in the
upstream-side part mounting work region is lifted up and conveyed
by the lift conveyance means to the workpiece conveyance dolly
provided in the downstream-side part mounting work region, parts of
a driving mechanism and a suspension are mounted on the
workpiece.
[0010] In the invention according to a fifth aspect, preferably, a
serving conveyance path provided for movement therealong of a part
serving carriage is connected at opposite ends to a mounting work
start position and a mounting work end position of each of the
substantially U-shaped conveyance paths so that the serving
carriage is allowed to move into each of the substantially U-shaped
conveyance path from the mounting work start position and to be
conveyed out into the serving conveyance path from the mounting
work end position.
[0011] In the invention according to a sixth aspect, there is
provided a part mounting method for mounting parts onto a workpiece
while the workpiece is moved along conveyance paths, wherein a
plurality of substantially U-shaped conveyance paths is formed by
providing the conveyance paths with return bends, the method
comprising the steps of: organizing a working group allotted to one
workpiece moving along the substantially U-shaped conveyance paths,
the working group is composed of one or more mounting operators
engaged in a mounting work, beginning at a mounting work start
position and ending at a mounting work end position, for mounting
predetermined plural parts on the workpiece, and a plurality of
extra operators; and performing the mounting work by the working
group.
[0012] In the invention according to a seventh aspect, preferably,
the working group further includes, additional to the mounting
operator or operators, a part transporting operator for
transporting a part from a part storage site to the mounting
operator or operators.
Advantageous Effects of Invention
[0013] In the invention according to the first aspect, the
conveyance paths are provided with the return bends to thereby form
the plurality of substantially U-shaped conveyance paths having the
first return bends. With this arrangement, the part items to be
mounted to each workpiece can be divided and distributed to the
plurality of substantially U-shaped conveyance paths. Thus, the
total number of part items to be mounted in each of the
substantially U-shaped conveyance paths can be reduced. Even when
the number of part items to be mounted on each workpiece is large,
the work load on the human operators engaged in mounting work in
each of the substantially U-shaped conveyance paths can be properly
suppressed.
[0014] Furthermore, the upstream-most substantially U-shaped
conveyance path is connected to the downstream-most substantially
U-shaped conveyance path so that the workpiece conveyance dolly is
allowed to circulate along the conveyance paths. With this
arrangement, when a mounting operation performed in the
downstream-most substantially U-shaped conveyance path for mounting
parts onto the workpiece has been completed, the workpiece is
removed from the workpiece conveyance dolly and the empty or
workpiece-free workpiece conveyance dolly is circulated toward the
upstream-most substantially U-shaped conveyance path.
[0015] Upon arrival of the empty workpiece conveyance dolly at the
upstream-most substantially U-shaped conveyance path, a new
workpiece is placed on the empty workpiece conveyance dolly, and
the workpiece conveyance dolly carrying thereon the workpiece is
moved to advance along the upstream-most substantially U-shaped
conveyance path. By thus quickly returning the workpiece conveyance
dolly, which has been emptied at the downstream-most substantially
U-shaped conveyance path, to the upstream-most substantially
U-shaped conveyance path, it is possible to increase the
productivity.
[0016] In the invention according to the second aspect, the
workpiece carried on the workpiece conveyance dolly provided in the
upstream-side part mounting work region is conveyed by the lift
conveyance means to the workpiece conveyance dolly provided in the
downstream-side part mounting work region. With this arrangement,
the total number of parts to be mounted on each workpiece can be
divided and distributed to the plural part mounting work
regions.
[0017] With this parts distribution, it is possible to reduce the
number of parts to be mounted on each workpiece in each of the part
mounting work regions. Even when the number of parts to be mounted
on each workpiece is large, the work load on the human operator or
operators engaged in a work in each of the substantially U-shaped
conveyance paths can be properly suppressed.
[0018] In the invention according to the third aspect, the
workpiece carried on the workpiece conveyance dolly in the
upstream-side part mounting work region is lifted up and conveyed
by the lift conveyance means to the workpiece conveyance dolly
provided in the downstream-side part mounting work region. With
this arrangement, while the workpiece is conveyed in a lifted
state, parts can be mounted on a lower portion of the workpiece.
The part mounting operation can be achieved with increased
efficiency and the productivity is increased.
[0019] In the invention according to the fourth aspect, the
workpiece is an automobile body and the parts are mounted on the
automobile body. It is known that the number of part items involved
in the automobile is relatively large. By using the part mounting
facility for mounting part items onto the automobile body, the work
load on the human operator or operators can be properly suppressed,
the part mounting operation can be achieved with increased
efficiency, and the productivity is increased.
[0020] Some automobile parts, such as the driving mechanism and the
suspension, are mounted on the workpiece (automobile body) from
below. According to the invention, since the driving mechanism and
the suspension and other lower part items can be mounted to the
lower portion of the workpiece while the workpiece is conveyed in a
lifted state, the operation to mount the driving mechanism and the
suspension onto the workpiece can be achieved with high efficiency
and, hence, the productivity is increased.
[0021] In the invention according to the fifth aspect, the serving
conveyance path is connected to each of the substantially U-shaped
conveyance path, and the serving carriage is movably provided on
the serving conveyance path. With this arrangement, the serving
carriage is allowed to move into the substantially U-shaped
conveyance path from the mounting word start position and to be
conveyed out into the serving conveyance path from the mounting
work end position.
[0022] The serving carriage is movable along with the workpiece
conveyance dolly so that the human operator or operators can
speedily and easily obtain a necessary part from the serving
carriage. This will further increase the mounting workability.
Furthermore, the human operator or operators are freed from a
time-consuming duty to walk to a part storage site and, hence, the
work load on the human operator or operators can be properly
suppressed.
[0023] In the invention according to the sixth aspect, one or more
mounting operators are allotted to one workpiece moving along the
plurality of substantially U-shaped conveyance paths having the
return bends. The one or more mounting operators are engaged in the
mounting work, beginning at the mounting work start position and
ending at the mounting work end position, for mounting
predetermined plural parts to the workpiece while the workpiece
moves along each of the substantially U-shaped conveyance path.
[0024] Furthermore, a working group composed of the one or more
mounting operators and a plurality of extra operators is organized
and the mounting work is performed by the working group. When one
of the mounting operators is not available, one of the extra
operators will be engaged in the mounting work in place of the
unavailable mounting operator. A desired level of part mounting
workability can thus be maintained without lowering the
productivity.
[0025] In the invention according to the seventh aspect, the
working group further includes the part transporting operator
engaged in a work for transporting a necessary part from the part
storage site to the mounting operator. The mounting operator is
freed from a time-consuming duty to walk to the part storage site
and, hence, the work load on the mounting operator can be properly
suppressed.
[0026] In general, a part transporting operation is easy to perform
as compared to the part mounting operation. By properly allotting
or distributing the work depending on the workability of each human
operator, it is possible to efficiently use the ability of each
human operator.
BRIEF DESCRIPTION OF DRAWINGS
[0027] FIG. 1 is a plan view showing a part mounting facility
according to the present invention;
[0028] FIG. 2 is a plan view of a first part mounting work region
shown in FIG. 1;
[0029] FIG. 3 is a view showing a workpiece carried on a workpiece
conveyance dolly shown in FIG. 1;
[0030] FIG. 4 is a view illustrative of the manner in which parts
are mounted to the workpiece from below while the workpiece is
lifted up by a lift conveyance means shown in FIG. 1;
[0031] FIG. 5 is a perspective view illustrative of the manner in
which an engine unit and other parts are mounted to the workpiece
while the workpiece is lifted up by the lift conveyance means shown
in FIG. 1;
[0032] FIG. 6 is a plan view illustrative of the manner in which
serving dollies are transported together with a workpiece
conveyance dolly according to the invention; and
[0033] FIG. 7 is a plan view showing a part mounting method
according to the present invention.
DESCRIPTION OF EMBODIMENTS
[0034] A certain preferred embodiment of the present invention will
be described below in greater detail with reference to the
accompanying sheets of drawings.
Embodiment
[0035] Workpiece conveyance dollies 41 are designed for accepting
single or plural human operators 61 depending on the kind of
workpiece 42. However, to facilitate understanding, in the
embodiment shown in FIGS. 1 and 2, only one human operator 61 rides
on each of the workpiece conveyance dollies 41. Furthermore, the
human operator 61 is illustrated in FIGS. 1 and 2 as riding on only
selected one or more workpiece conveyance dollies 41.
[0036] Referring now to FIG. 1, a part mounting facility 10
generally comprises a first part mounting facility 11 provided on
an upstream side, a second part mounting facility 12 provided on a
downstream side of the first part mounting facility 11, and a lift
conveyance means 14 provided between the first part mounting
facility 11 and the second part mounting facility 12.
[0037] The part mounting facility 10 further includes a first part
serving facility 16 provided adjacent to the first part mounting
facility 11, a second part serving facility 21 provided adjacent to
the second part mounting facility 12, and a lifter part serving
facility 25 provided between the first part serving facility 16 and
the second part serving facility 21.
[0038] As shown in FIG. 2, the first part mounting facility 11
includes a plurality of substantially U-shaped first conveyance
paths 34 having first return bends 33, which is formed by providing
first conveyance paths (conveyance paths) 32 with first return
bends (return bends) 33 in a first part mounting work region 31.
The first return bends 33 is formed into a semicircular-arc
shape.
[0039] In the first part mounting facility 11, each pair of
adjacent ones of the plurality of substantially U-shaped first
conveyance paths 34 is connected by a first connecting path
(conveyance path) 36. The first connecting path 36 is formed into a
semicircular-arc shape in the same manner as the first return bends
33.
[0040] Furthermore, in the first part mounting facility 11, an
upstream-most substantially U-shaped first conveyance path 34 among
the connected substantially U-shaped first conveyance paths 34 is
connected to a downstream-most substantially U-shaped first
conveyance path 34 by a first circulation path (conveyance path)
37. To facilitate understanding of the structure, the upstream-most
substantially U-shaped first conveyance path 34 will be hereinafter
designated by 34A and the downstream-most substantially U-shaped
first conveyance path 34 will be hereinafter designed by 34B.
[0041] The upstream-most substantially U-shaped first conveyance
path 34A is provided in a first upstream-side mounting work area
31A of the first part mounting work region 31, and the
downstream-most substantially U-shaped first conveyance path 34B is
provided in a first downstream-side mounting work area 31B of the
first part mounting work region 31.
[0042] More specifically, one end 37a of the first circulation path
37 is connected to a first mounting work start position P1 of the
upstream-most substantially U-shaped first conveyance path 34A, and
an opposite end 37b of the first circulation path 37 is connected
to a first mounting work end position P2 of the downstream-most
substantially U-shaped first conveyance path 34B.
[0043] The workpiece conveyance dollies 41 are provided so as to be
movable along the upstream-most first conveyance path 34A, the
first connecting path 36, the downstream-most first conveyance path
34B, and the first circulation path 37. Thus, the workpiece
conveyance dollies 41 can be circulated along the upstream-most
first conveyance path 34A, the first connecting path 36, the
downstream-most first conveyance path 34B, and the first
circulation path 37, as indicated by arrowheads. As shown in FIG.
3, each of the workpiece conveyance dollies 41 is provided with a
lifter 58 and a workpiece (specifically, a body of an automobile)
42 is carried on the lifter 58.
[0044] On the upstream-most first conveyance path 34A shown in FIG.
2, an electric component, such as a battery for hybrid vehicles, is
mounted to each individual workpiece 42. On the downstream-most
first conveyance path 34B, an interior part, such as an instrument
panel, and other parts are mounted to each individual workpiece
42.
[0045] In the first part mounting facility 11, each of the
workpiece conveyance dollies 41 is circulated along the
upstream-most first conveyance path 34A, the first connecting path
36, the downstream-most first conveyance path 34B, and the first
circulation path 37. With this arrangement, after the part mounting
work performed on each individual workpiece 42 is finished while
the workpiece 42 is in the downstream-most substantially U-shaped
conveyance path 34B, the workpiece 42 is removed from the workpiece
conveyance dolly 41, and the workpiece conveyance dolly 41, which
is now free from a workpiece, is circularly moved back to the
upstream-most substantially U-shaped first conveyance path 34A.
[0046] Upon arrival of the workpiece-free workpiece conveyance
dolly 41 at the upstream-most substantially U-shaped first
conveyance path 34A, a new workpiece 41 is mounted on the
workpiece-free workpiece conveyance dolly 41. The workpiece
conveyance dolly 41 with the workpiece 41 carried thereon is then
moved along the upstream-most substantially U-shaped first
conveyance path 34A. The work conveyance dolly 41, which has become
empty or free from a workpiece at the downstream-most substantially
U-shaped first conveyance path 34B, can thus be quickly returned to
the upstream-most substantially U-shaped first conveyance path 34A,
so that the productivity can be increased.
[0047] As shown in FIG. 1, the second part mounting facility 12 is
disposed downstream of the first part mounting facility 11.
Likewise the first part mounting facility 11, the second part
mounting facility 12 includes a plurality of substantially U-shaped
second conveyance paths 46 having second return bends 47, which is
formed by providing second conveyance paths (conveyance paths) 46
with first return bends (return bends) 47 in a second part mounting
work region (part mounting work region) 45. The second return bends
47 is formed into a semicircular-arc shape in the same manner as
the first return bends 33.
[0048] In the second part mounting facility 12, each pair of
adjacent ones of the plurality of substantially U-shaped second
conveyance paths 48 is connected by a second connecting path
(conveyance path) 51. The second connecting path 51 is formed into
a semicircular-arc shape in the same manner as the second return
bends 47.
[0049] Furthermore, in the second part mounting facility 12, an
upstream-most substantially U-shaped second conveyance path 48
among the connected substantially U-shaped second conveyance paths
48 is connected to a downstream-most substantially U-shaped second
conveyance path 48 by a second circulation path (conveyance path)
52. To facilitate understanding of the structure, the upstream-most
substantially U-shaped second conveyance path 48 will be
hereinafter designated by 48A and the downstream-most substantially
U-shaped second conveyance path 48 will be hereinafter designed by
48B.
[0050] The upstream-most substantially U-shaped second conveyance
path 48A is provided in a second upstream-side mounting work area
45A of the second part mounting work region 45, and the
downstream-most substantially U-shaped second conveyance path 48B
is provided in a first downstream-side mounting work area 45B of
the second part mounting work region 45.
[0051] More specifically, one end 52a of the second circulation
path 52 is connected to a second mounting work start position P3 of
the upstream-most substantially U-shaped second conveyance path
48A, and an opposite end 52b of the second circulation path 52 is
connected to a second mounting work end position P4 of the
downstream-most substantially U-shaped second conveyance path
48B.
[0052] The workpiece conveyance dollies 41 are provided so as to be
movable along the upstream-most second conveyance path 48A, the
second connecting path 51, the downstream-most second conveyance
path 48B, and the second circulation path 52. Thus, the workpiece
conveyance dollies 41 can be circulated along the upstream-most
second conveyance path 48A, the second connecting path 51, the
downstream-most second conveyance path 48B, and the second
circulation path 52, as indicated by arrowheads.
[0053] On the upstream-most second conveyance path 48A, for
example, an exterior part, such as a pair of headlights, and other
parts are mounted to each individual workpiece 42. On the
downstream-most second conveyance path 48B, for example, bumpers
and other parts are mounted to each individual workpiece 42.
Furthermore, at a downstream position 52c of the downstream-most
second conveyance path 48B, for example, window-panes, tires, and
doors are mounted to each individual workpiece 42.
[0054] In the second part mounting facility 12, by circulating the
work conveyance dollies 41 as indicated by arrowheads in the same
manner as done in the first part mounting facility 11, each of the
empty or workpiece-free work conveyance dollies 41 is quickly
returned to the upstream-most substantially U-shaped second
conveyance path 48A, so that the productivity can be increased.
[0055] In the first part mounting facility 11, the plurality of
first conveyance paths 32 are provided with the plurality of first
return bends 33 to thereby form the plurality of substantially
U-shaped first conveyance paths 34 having the first return bends
33. Furthermore, in the second part mounting facility 12, the
plurality of second conveyance paths 46 are provided with the
plurality of second return bends 47 to thereby form the plurality
of substantially U-shaped second conveyance paths 48 having the
second return bends 47.
[0056] With this arrangement, the part items to be mounted to each
workpiece 42 can be divided into two groups, one for the plurality
of substantially U-shaped first conveyance paths 34 and the other
for the plurality of substantially U-shaped second conveyance paths
48. Thus, the total number of part items to be mounted in the
substantially U-shaped first conveyance paths 34 or the
substantially U-shaped second conveyance paths 48 can be reduced.
In the case where the number of part items to be mounted on each
workpiece 42 is large, work load on the human operators engaged in
mounting work in each of the substantially U-shaped first and
second conveyance paths 34, 48 can be properly suppressed.
[0057] The lift conveyance means 14 is proved in a lift part
mounting work region 49 between the first part mounting facility 11
and the second part mounting facility 12. The lift conveyance means
14 includes a lift conveyance path 55 having one end 55a connected
to a conveying-out position P5, an opposite end 55b of the lift
conveyance path 55 being connected to the second mounting work
start position P3 of the second part mounting facility 12. The
conveying-out position P5 is located on a downstream side of the
first mounting work end position P2 of the first part mounting
facility 11.
[0058] A workpiece conveyance lift 56 is movably provided on the
lift conveyance path 55. The workpiece conveyance lift 56 is
configured to move along the lift conveyance path 55 and, at the
same time, descends to a height of the workpiece 42 where locking
prongs at a lower end of the workpiece conveyance lift 56 are
located below the workpiece 42.
[0059] In this condition, the workpiece conveyance lift 56 is
stopped or synchronized with the movement of the workpiece 42,
while at the same time, the lifter 58 (FIG. 3) of the workpiece
conveyance dolly 41 moves downward to thereby allow the workpiece
42 to be set on the locking prongs. With the workpiece 42 being set
on the locking prongs, the workpiece conveyance lift 56 moves
upward while traveling along the lift conveyance path 55 whereby
the workpiece 42 is lifted up from the workpiece conveyance dolly
41 by the workpiece conveyance lift 56. The thus lifted workpiece
42 is transferred to the workpiece conveyance dolly 41 standing-by
at the second mounting work start position P3.
[0060] At the second mounting work start position P3, the aforesaid
operations performed by the workpiece conveyance lift 56 to lift up
the workpiece 42 from the workpiece conveyance dolly 41 are
performed in a reverse manner so that the workpiece 42 is
transferred from the work conveyance lift 56 to the workpiece
conveyance dolly 41.
[0061] As shown in FIGS. 4 and 5, the workpiece 42 is lifted up by
the workpiece conveyance lift 56 and, thereafter, at a lower part
mounting region 59 disposed downstream of the conveying-out
position P5 (FIG. 1), lower parts (such as connecting joints for
driving) excluding an engine unit 63 and a rear suspension 64 are
mounted on the workpiece 42 from below.
[0062] During that time, depending on the position on the workpiece
42 where a lower part is to be mounted, it may be convenient for a
human operator 61 to perform a mounting operation while standing on
the lifter 58 of the workpiece conveyance dolly 41. The human
operator 61 is allowed to perform the mounting operation without
taking an unusual posture and, hence, the work load on the human
operator 61 can be reduced.
[0063] In the embodiment shown in FIGS. 1 and 2, only one human
operator 61 mounts on each of the selected workpiece conveyance
dollies 41 in order to facilitate understanding. However, two or
more human operators 61 may ride on the workpiece conveyance dolly
41 to perform the mounting operation.
[0064] As shown in FIG. 4, after the lower parts are mounted on the
workpiece 42, the workpiece 42 is transport to an engine mounting
position P6 (FIG. 1). As shown in FIG. 5, at the engine mounting
position P5, the engine unit 63 and the rear suspension 64 are
lifted up by two lifters 65 and 66, respectively. While keeping
this condition, the engine unit 63 and the rear suspension 64 are
mounted on the workpiece 42 from below. The engine unit 63 includes
an engine, a transmission and a clutch that are integrated into a
unitary structure, and a front suspension integrally formed with
the unitary structure.
[0065] Since the lift conveyance means 14 lifts up and carries the
workpiece 42 from the workpiece conveyance dolly 41 in the first
part mounting facility 11 to the workpiece conveyance dolly 41 in
the second part mounting facility 12, the lower parts, the engine
unit 63 and the rear suspension 64 can be mounted to a lower
portion of the workpiece 42 during conveyance of the workpiece 42
by the lift conveyance means 41. This arrangement increases the
efficiency of the part mounting operation relative to the workpiece
42 and improves the productivity.
[0066] Furthermore, since the workpiece 42 carried on the workpiece
conveyance dolly 41 in the first part mounting facility 11 can be
transported by the lift conveyance means 14 to the workpiece
conveyance dolly 41 in the second part mounting facility 12, the
part items to be mounted to each workpiece 42 are divided and
distributed to the first part mounting facility 11 and the second
part mounting facility 12.
[0067] By thus allocating the part items, it is possible to reduce
the number of parts to be mounted on each workpiece 42 in the first
part mounting facility 11 or the second part mounting facility 12.
In the case where the number of parts to be mounted on each
individual workpiece 42 is relatively large, the work load on the
human operators engaged in mounting work in the first part mounting
facility 11 or the second part mounting facility 12 can be properly
suppressed.
[0068] As shown in FIG. 2, the first part serving facility 16 is
disposed adjacent to the first part mounting facility 11. The first
part serving facility 16 includes an upstream-side first part
serving section 17, and a downstream-side first part serving
section 18 disposed on a downstream side of the upstream-side first
part serving section 17.
[0069] The upstream-side first part serving section 17 includes an
upstream-side first serving conveyance path (serving conveyance
path) 71 having one end 71a connected to the first mounting work
start position P1 of the upstream-most first conveyance path 34A of
the first part mounting facility 11, an opposite end 71b of the
upstream-side first serving conveyance path 71 being connected to a
first mounting work end position P7 of the upstream-most first
conveyance path 34A of the first part mounting facility 11.
[0070] Serving carriages 72 are movably provided on the
upstream-side first serving conveyance path 71 so that the serving
carriages 72 can be transported onto the upstream-most
substantially U-shaped first conveyance path 34A from the first
mounting work start position P1 and, thereafter, the serving
carriages 72 can be conveyed out from the first mounting work end
position P7 of the upstream-most substantially U-shaped first
conveyance path 34A onto the upstream-side first serving path
71.
[0071] As shown in FIG. 6, in the upstream-most substantially
U-shaped first conveyance path 34A, two serving carriages 72 are
placed in front and behind each of the workpiece conveyance dollies
41 and the serving carriages 72 are movable along with each
workpiece conveyance dolly 41. Each of the serving carriages 72 has
two parts storage boxes 73 at opposite lateral ends 72a thereof for
storing therein parts to be mounted to each individual workpiece
42.
[0072] This arrangement allows the human operator 61 (FIG. 1) to
quickly pick up a necessary part to be mounted on the workpiece 42,
which will further increase the assembly workability. Furthermore,
the human operator 61 is now freed from a time-consuming duty to
walk to a part storage site and, hence, the work load on the human
operator 61 can be properly suppressed.
[0073] Referring back to FIG. 2, the downstream-side first part
serving section 18 includes a downstream-side first serving
conveyance path (serving conveyance path) 75 having one end 75a
connected to a first mounting work start position P8 of the
downstream-most first conveyance path 34B of the first part
mounting facility 11, an opposite end 75b of the downstream-side
first serving conveyance path 75 being connected to the first
mounting work end position P2 of the downstream-most first
conveyance path 34B of the first part mounting facility 11.
[0074] Serving carriages 72 are movably provided on the
downstream-side first serving conveyance path 75 so that the
serving carriages 72 can be transported onto the downstream-most
substantially U-shaped first conveyance path 34B from the first
mounting work start position P8 and, thereafter, the serving
carriages 72 can be conveyed out from the first mounting work end
position P2 of the downstream-most substantially U-shaped first
conveyance path 34B onto the downstream-side first serving path
75.
[0075] With this arrangement, in the downstream-most substantially
U-shaped first conveyance path 34B, two of the serving carriages 72
can be moved along with each of the workpiece conveyance dollies
41, so that the human operator 61 is allowed to quickly pick up a
necessary part to be mounted on the workpiece 42. This will further
increase the assembly workability. Furthermore, the human operator
61 is freed from a time-consuming duty to walk to the part storage
site and, hence, the work load on the human operator 61 can be
properly suppressed.
[0076] As shown in FIG. 1, the second part serving facility 21 is
provided adjacent to the second part mounting facility 12. The
second part serving facility 21 includes an upstream-side second
part serving section 22 and a downstream-side second part serving
section 23 disposed on a downstream side of the upstream-side
second part serving section 22.
[0077] The upstream-side second part serving section 22 includes an
upstream-side second serving conveyance path (serving conveyance
path) 77 having one end 77a connected to the second mounting work
start position P3 of the upstream-most second conveyance path 48A
of the second part mounting facility 12, an opposite end 77b of the
upstream-side second serving conveyance path 77 being connected to
a second mounting work end position P9 of the upstream-most second
conveyance path 48A of the second part mounting facility 12.
[0078] Serving carriages 72 are movably provided on the
upstream-side second serving conveyance path 77 so that the serving
carriages 72 can be transported onto the upstream-most
substantially U-shaped second conveyance path 48A from the second
mounting work start position P3 and, thereafter, the serving
carriages 72 can be conveyed out from the second mounting work end
position P9 of the upstream-most substantially U-shaped second
conveyance path 48A onto the upstream-side second serving path
77.
[0079] With this arrangement, in the upstream-most substantially
U-shaped second conveyance path 48A, two of the serving carriages
72 are movable along with each workpiece conveyance dolly 41. The
human operator 61 is allowed to quickly pick up a necessary part to
be mounted on the workpiece 42, which will further increase the
assembly workability. Furthermore, the human operator 61 is freed
from a time-consuming duty to walk to the part storage site and,
hence, the work load on the human operator 61 can be properly
suppressed.
[0080] The downstream-side second part serving section 23 includes
a downstream-side second serving conveyance path (serving
conveyance path) 78 having one end 78a connected to a second
mounting work start position P10 of the downstream-most second
conveyance path 48B of the second part mounting facility 12, an
opposite end 78b of the downstream-side second serving conveyance
path 78 being connected to the second mounting work end position P4
of the downstream-most second conveyance path 48B of the second
part mounting facility 12.
[0081] Serving carriages 72 are movably provided on the
downstream-side second serving conveyance path 78 so that the
serving carriages 72 can be transported onto the downstream-most
substantially U-shaped second conveyance path 48B from the second
mounting work start position P10 and, thereafter, the serving
carriages 72 can be conveyed out from the second mounting work end
position P4 of the downstream-most substantially U-shaped second
conveyance path 48B onto the downstream-side second serving path
77.
[0082] With this arrangement, in the downstream-most substantially
U-shaped second conveyance path 48B, two of the serving carriages
72 can be moved along with each of the workpiece conveyance dollies
41, so that the human operator 61 is allowed to quickly pick up a
necessary part to be mounted on the workpiece 42. This will further
increase the assembly workability. Furthermore, the human operator
61 is freed from a time-consuming duty to walk to the part storage
site and, hence, the work load on the human operator 61 can be
properly suppressed.
[0083] The lifter part serving facility 25 is provided adjacent to
the lifter conveyance means 14. The lifter part serving facility 25
includes a lift serving conveyance path (serving conveyance path)
81 having one end 81a connected to the conveying-out position P5.
The conveying-out position P5 is connected to the lift conveyance
path 55 of the lift conveyance means 14. An opposite end 81b of the
lift serving conveyance path 81 is connected to the lift conveyance
path 55 at the engine mounting position P6.
[0084] Serving carriages 82 are movably provided on the lift
serving conveyance path 81 so that the serving carriages 82 can be
transported onto the lift conveyance path 55 from the conveying-out
position P5 and, thereafter, the serving carriages 82 can be moved
out from the lift conveyance path 55 at the engine mounting
position P6 and transferred onto the lift serving conveyance path
81. The serving carriages 82 can thus be moved along with the
individual workpieces 42 by using the workpiece conveyance lift
56.
[0085] Furthermore, in the illustrated embodiment, the workpiece 42
is a body of an automobile and the part mounting facility 10 are
arranged to mount automobile parts to the body of the automobile.
It is known that the number of part items of the automobile is
relatively large. The part mounting facility 10 is used for
mounting part items onto an automobile body to thereby suppress the
work load on the human operators 61 and insure a highly efficient
part mounting operation and increased productivity.
[0086] Some automobile parts, such as the engine unit (driving
mechanism) 63 and the rear suspension (suspension) 64 (FIG. 5), are
mounted on the automobile body from below. According to the
invention, since the engine unit 63, the rear suspension 64 and
other lower part items can be mounted to a lower portion of the
workpiece 42 while the workpiece 42 is conveyed in a lifted state,
the operation to mount the engine unit 63, the rear suspension 64
and the lower part item to the workpiece 42 can be achieved with
high efficiency and, hence, the productivity is increased.
[0087] A part mounting method of the invention that can be carried
out by the part mounting facility 10 will be described with
reference to FIG. 7. The workpiece conveyance dollies 41 are
designed for accepting single or plural human operators 61
depending on the kind of workpiece 42. However, to facilitate
understanding, in the embodiment shown in FIG. 7, only one human
operator 61 rides on each of the workpiece conveyance dollies 41.
Furthermore, the human operator 61 is illustrated in FIG. 7 as
riding on only selected one or more workpiece conveyance dollies
41.
[0088] As shown in FIG. 7, the part mounting facility 10 includes
the upstream-most substantially U-shaped first conveyance path 34A
provided in the first upstream-side mounting work area 31A. The
upstream-side first part serving section 17 is provided adjacent to
the first conveyance path 34A. Furthermore, the downstream-most
first conveyance path 34B is provided in the first downstream-side
mounting work area 31B, and the downstream-side first part serving
section 18 is provided adjacent to the first conveyance path
34B.
[0089] Similarly, the upstream-most substantially U-shaped second
conveyance path 48A is provided in the second upstream-side
mounting work area 45A. The upstream-side second part serving
section 22 is provided adjacent to the second conveyance path 48A.
Furthermore, the downstream-most second conveyance path 48B is
provided in the second downstream-side mounting work area 45B, and
the downstream-side second part serving section 23 is provided
adjacent to the second conveyance path 48B. The lift conveyance
means 14 is provided in the lift part mounting work region 49, and
the lifter part serving facility 25 is provided adjacent to the
lift conveyance means 14.
[0090] In the part mounting facility 10, the workpiece conveyance
dollies 41 are travelling one after another from an upstream side
toward a downstream side along the upstream-most first conveyance
path 34A, the downstream-most first conveyance path 34B, the
upstream-most second conveyance path 48A, and the downstream-most
second conveyance path 48B.
[0091] When each workpiece conveyance dolly 41 moves from the first
mounting start position P1 into the first conveyance path 34a, one
workpiece 42 is placed on the workpiece conveyance dolly 41. At the
same time, one or more human operators 61 ride on the workpiece
conveyance dolly 41 for achieving necessary part mounting
operations. Likewise, for each of the workpiece conveyance dollies
41 coming in sequence from the upstream side into the first
mounting work start position P1, one workpiece 42 is placed on the
workpiece conveyance dolly 41 and one or more human operators 61
ride on the same workpiece conveyance dolly 41. The human operator
or operators 61 engage in a work to mount parts to the workpiece
42.
[0092] More specifically, in the first upstream-side mounting work
area 31A, electric parts, such as a battery for hybrid vehicles,
are mounted on the workpiece (automobile body). In the first
conveyance path 34A, two serving carriages 72 are provided at the
front and behind each workpiece conveyance dolly 41 and the serving
carriages 72 are moved along with the workpiece conveyance dolly
41.
[0093] While the workpiece conveyance dolly 41 advances along the
first conveyance path 34A from the first mounting work start
position P1 to the first mounting work end position P7, the
electric parts, such as the battery for hybrid vehicles, are
mounted on the workpiece 42 by the human operator or operators 61
while moving along with the workpiece conveyance dolly 41. Since
the parts to be mounted on the workpiece 42 are carried on the
serving carriages 72 moving along with the workpiece conveyance
dolly 41, the part mounting operation can be achieved with
increased efficiency.
[0094] Those parts (small parts, for example), which are not
carried on the serving carriages 72, are stored in parts storage
boxes 85 provided in the first upstream-side mounting work area
31A, so that a human operator 61 engaged exclusively in part
serving work serves the parts from the parts storage boxes 85 onto
the workpiece conveyance dolly 41. By thus serving the small parts,
the efficiency of the part mounting operation is further increased.
When the workpiece conveyance dolly 41 arrives at the first
mounting work end position P7 and the part mounting work for the
workpiece 42 has been completed, the human operator or operators 61
return to the first mounting work start position P1 as indicated by
the arrow A. In this instance, because the first conveyance path
34A is substantially U-shaped, the distance L between the first
mounting work end position P7 and the first mounting work start
position P1 can be made relatively short. This will allow the human
operator or operators 61 to cut down its or their traveling
distance required when returning to the first mounting work start
position P1. The work load on the human operator or operators can
be reduced and the productivity is increased.
[0095] In a like manner as done in the first conveyance path 34a in
the first upstream-side mounting work area 31A, interior parts,
such as an instrument panel, and other part items are mounted on
the workpiece 42 in the downstream-most first convenience path 34B,
and lower parts, an engine unit 63 (FIG. 5) and a rear suspension
64 are mounted on a lower portion of the workpiece 42 in the lift
conveyance means 14.
[0096] Subsequently, in the upstream-most second conveyance path
48A, exterior parts, such as headlights, and other parts are
mounted on the workpiece 42. Similarly, in the downstream-most
second conveyance path 48B, bumpers and other parts are mounted on
the workpiece 42.
[0097] Finally, at the position 52c located downstream of the
downstream-most second conveyance path 48B, window-panes, tires,
door and other parts are mounted on the workpiece to thereby
complete the part mounting work for the workpiece (automobile body)
42.
[0098] As described above, one human operator 61 is allocated to
each workpiece conveyance dolly 41 as the workpiece conveyance
dolly 41 moves along the upstream-most first conveyance path 34A,
the downstream-most first conveyance path 34B, the lift conveyance
means 14, the upstream-most second conveyance path 48A, and the
downstream-most second conveyance path 48B. While one workpiece 42
carried on each workpiece conveyance dolly 41 advances successively
along the substantially U-shaped conveyance paths 34A, 34B, 48A and
48B, the allocated human operator 61 perform a part mounting
operation to mount predetermined plural parts onto the workpiece
42, beginning at each of the mounting work start position and
ending at the corresponding mounting work end position.
[0099] In the embodiment shown in FIG. 7, one human operator 61 is
allocated to each workpiece 42. This embodiment is not restrictive
and two or more human operators 61 may be allocated to each
workpiece 42.
[0100] A working group for the substantially U-shaped conveyance
paths 34a, 34B, 48A and 48B is formed or organized by one or plural
human operators 61 engaged in a part mounting work for mounting
predetermined plural parts on each workpiece 42, and a plurality of
additional or extra human operators. In the case where one of the
human operators 61 is not available, one of the extra human
operators in the working group will engage in the part mounting
work in place of the unavailable human operator 61. Thus, a desired
level of mounting workability can be maintained without lowering
the productivity.
[0101] The working group also includes a plurality of part
transporting operators 62 in addition to the human operators 61
engaged in the part mounting work. The operators 61 will be
hereinafter referred to as "mounting operators". The part
transporting operators 62 serve to transport necessary parts from
the part storage boxes (the part storage sites) 85 to the mounting
operators 61. There is no need for the mounting operators 61 to
walk to the part storage site for getting the necessary part. The
work load on the mounting operators 61 can thus be properly
suppressed.
[0102] In general, a part transporting operation performed to
transport parts to the mounting operators 61 is easier than a part
mounting operation performed to mount parts on the workpiece 42. By
properly allotting or distributing the work depending on the
workability of each human operator 61, 62, it is possible to
efficiently use the ability of each human operator 61, 62.
[0103] The present invention should by no means be limited to the
illustrated embodiment, but various changes and modifications are
possible. For example, the shapes and configurations of the part
mounting facility 10, the lift conveyance means 14, the first
conveyance paths 32, the first return bends (return bends) 33, the
substantially U-shaped first conveyance paths 34 (34A, 34B), the
workpiece conveyance dollies 41, the workpiece 42, the second
conveyance paths 46, the second return bends 47, the substantially
U-shaped second conveyance paths 48 (48A, 48B), the serving
carriages 72, 82, the first serving conveyance paths 72, 75, the
second serving conveyance paths 77, 78, and the lift serving
conveyance path 81 are not limited to those described above with
respect to the illustrated embodiment, but various changes and
modifications are possible.
INDUSTRIAL APPLICABILITY
[0104] With the arrangements so far described, the present
invention is particularly suitable for application in a part
mounting facility and a part mounting method wherein parts are
mounted on each workpiece carried on a workpiece conveyance dolly
while the dolly is moved along a conveyance path.
REFERENCE SIGNS LIST
[0105] 10: part mounting facility [0106] 14: lift conveyance means
[0107] 31: first part mounting work region (part mounting work
region) [0108] 31A: first upstream-side mounting work area [0109]
31B: first downstream-side mounting work area [0110] 32: first
conveyance path (conveyance path) [0111] 33: first return bend
(return bend) [0112] 34 (34A, 34B): substantially U-shaped first
conveyance path (conveyance path) [0113] 36: first connecting path
(conveyance path) [0114] 37: first circulation path (conveyance
path) [0115] 41: workpiece conveyance dolly [0116] 42: workpiece
[0117] 45: second part mounting work region (part mounting work
region) [0118] 46: second conveyance path (conveyance path) [0119]
47: second return bend (return bend) [0120] 48 (48A, 48B):
substantially U-shaped second conveyance path (conveyance path)
[0121] 51: second connecting path (conveyance path) [0122] 52:
second circulation path (conveyance path) [0123] 72, 82: serving
carriage [0124] 71, 75: first serving conveyance path (serving
conveyance path) [0125] 77, 78: second serving conveyance path
(serving conveyance path) [0126] 81: lift serving conveyance path
(serving conveyance path)
* * * * *